The Key Manufacturing Technology Of Micro End Tool Of Poly-Crystalline Diamond And Some Micro-milling Test

Micro-milling tool is the key element to ensure the quality of micro-milling, and themanufacturing process of the tool becomes one of the difficulties that restricting the development ofmicro-milling technology. The low-stress braze welding technology between the PolyerystallineDiamond (PCD) Compact and the tool shank is an important step in the tool manufacturing procedure.An in-depth study about the braze welding technology is carried out in the paper. At the same time,the paper also concentrates on manufacturing of PCD micro end tools and some micro millingexperiments. The main content in this paper may be summarized as follows:Firstly，three-dimensional modeling of the triangular, quadrangular and hexagonal micro endmills are established in UG. Then the stress in brazing parts during the normal use is calculated byfinite element method in ABAQUS with triangular model as an example, providing a theoreticalvalidation for the actual trial basis.Secondly, the braze welding experiment is brought out at different brazing process parameters inorder to study the influence of brazing temperature, holding time, and pressure on shearing strength.The orthogonal brazing experiment shows that the three factors affect the shearing strength as follows:brazing temperature>holding time>pressure. It is found that the highest shear strength value251.19MPa could be achieved when the joint is brazed at780℃for14s under the pressure of2.23MPa. Then some temperature tests are discussed in case of stationary holding time and pressure.The results indicate that, with the increase of brazing temperature, the shearing strength increases. Thehighest quality welding joint can be achieved at780℃with few welding defects. The distribution ofelements on the brazing intersection is observed by means of SEM for further study.Thirdly, in the shaping step, a special tool fixture is designed, and specific steps of shaping ofmilling edges are determined. Following the manufacturing steps, micro milling tools with differentrake angles and clearance angles are manufactured by WEDM. The characteristic dimension of thetools is0.5mm. The problems which arise in the whole manufacturing process of PCD micro end millare summerized, in order to further improve the manufacturing process of PCD micro end mill.Lastly, micro milling experiment of the fine structure of typical straight slot is carried out tostudy milling performance of PCD micro mill which is shaped by WEDM.